Archive · 28 Sep 2026
Why Vehicle Delays Begin Before the Build Stage
Making a new vehicle is like building a very complicated puzzle with thousands of pieces.
Many Indian vehicle projects take longer than planned to reach customers.
Problems often become obvious when engineers assemble the first physical vehicles.
However, the problems usually started earlier in the computer design.
Fixing a design on a computer is faster and cheaper than changing tools and parts later.
The study says many build-stage problems could have been prevented through better 3D checks.
It recommends bringing engineers and suppliers together earlier.
It also suggests using small physical models for parts that are difficult to test digitally.
This could reduce rework, prototype costs and launch delays.
Vector Consulting Group says major Indian vehicle programmes often launch 9–15 months late, while complex programmes can slip 18–24 months.
Although 34%–47% of total delays emerge during tooled-up and pilot builds, many problems originate earlier in 3D design.
Fitment, assembly, manufacturability and serviceability issues become costlier after tooling and physical production begin.
The study says 40%–60% of build-stage issues could have been prevented during 3D design validation.
Recommended measures include limiting concurrent programmes, delaying 2D drawings until 3D maturity, strengthening technical leadership and involving suppliers earlier.
- Who
- Indian automotive Original Equipment Manufacturers, suppliers and specialist engineering teams; the findings were reported by Vector Consulting Group.
- What
- Vehicle development programmes are being delayed, with many build-stage problems traced to unresolved issues in earlier 3D design.
- When
- The study examines vehicle development practices and reports delays of 9–15 months for major programmes and 18–24 months for more complex programmes.
- Where
- The findings concern the Indian automotive industry.
- Why
- Delays arise from repeated design changes, supplier rework, unresolved cross-functional issues and problems discovered after tooling or physical builds begin.
- Major programme delays
- 9–15 months later than planned
- Complex programme delays
- 18–24 months later than planned
- Delay during build stages
- 34%–47% of total programme delay accumulates after tooled-up and pilot builds begin
- Preventable issues
- Respondents estimate 40%–60% of build-stage issues could have been prevented during 3D design
- Unresolved launch concerns
- 39% of respondents say products launch with unresolved fitment, serviceability or quality concerns
- Relaxed quality gates
- 47% acknowledge that quality gates are relaxed when schedules slip
- Digital NPD investment
- 93% of respondents have spent at least ₹50 crore on digital new product development tools over five years
- Supplier feedback
- 81% of surveyed Tier-1 suppliers say late Engineering Change Notices significantly increase project lead times